Hydrocarbon conversion process



March 22, v1949. J, w, MOORMAN 2,465,255

y HYDRocARBoN CONVERSION PRocEss Filed July 18, 1946 VOLO/V- l 3f 37 e v f IN VEN TOR. JsfPH M/Moo/PMAN l Yffm ATTOEJVEY Patented Mar. 22, 1949 .-HYnRocARBoN coNvnasIoN PRocEss f" Joseph W. Moorman, Alpine, J., assignor to The M. W. Kellogg Company, AJ ersey City, N. J., a corporation of Delaware Application July 1s, 194s,se,ria1 No 684,464

vor pulverulent particles of catalytic material are successively and cyclically circulated through a conversion and a regeneration zone. In the conversion zone, the particles of catalyst are contacted with the hydrocarbons undergoing cracking, or other conversion reactions, at an elevated temperature and for a period of time sufiicient to bring about the desired catalytic conversion,

A and which also results in the formation of a deposit of vaporizable and unvaporizable contaminants of carbonaceous material on the catalyst of complex composition including both carbon and hydrogen. Upon separation and withdrawal from the vapors undergoing conversion, the .used catalyst is passed to a regeneration zone and contacted therein with an oxygen-containing gas under suitable conditions to remove the carbonaceous deposit by combustion without detrimental-ly affecting the catalytic activity of the catalyst particles by overheating.

During the transfer of the used catalyst between the conversion and the regeneration zones, it is customary to subject it to a purging, or strip- 5 Claims. (Cl. l1Std- 52) ping, treatment with an inert gas, such as steam,

particles upon introduction to the regeneration I A. zone, and the provision of improvements in the mode o f operation and eliciency of the purging treatment is a primary object of this invention.

Heretofore, a method proposed for purging the ilnely divided catalyst generally involved simple countercurrent iiow of the used catalyst particles and the purging gas. Pursuant to the latter procedure, the used catalyst particles are permitted to fall through a vertical purging column in contact with an upwardly flowing stream of t-he purging medium. Invthis manner the used catalyst particles during their ow downwardly through the column are contacted with a stream of purging gas of constantly increasing purity 'from the standpoint vof the concentration of purgable material therein.

sldered by those skilled -in the art that this type From theoretical standpoints, it has heretofore advisedly been con- 2 of purging treatment should provide optimum results.

Contrary to the foregoing the present invention is based upon the discovery that substantially improved results may be attained by a modified form of operation which departs radically from the simple countercurrent flow type of operation heretofore proposed and used.

In accordance with the process provided by this invention the catalyst particles while at the elevated temperature to which they are heated in the conversion zone are flowed as a fluid mass of aerated particles downwardly in countercurrent contact with a stream of purging gas in a rst stage or preliminary purging procedure. Subsequent to this treatment the catalyst particles are injected intoa owing stream of gas which may be inert, such as steam, ue gas or the like, or an oxygen-containing gas, such as air, and contacted concurrently therewith and conveyed to a gas-solids separating means which may be the dilute catalyst phase in auid catalyst zone or a cyclone wherein substantially complete separation is made between the catalyst particles and the gas. Thereafter, the catalyst particles are injected intor a densephase bed of catalyst particles in a purging zone preferably superimposed immediately over the regenerating zone so that they are maintained in a iluid condition by the uncompressed highly heated gaseous products of combustion passing upwardly therethrough directly from the regen eration zone.- The time at which the catalyst particles is maintained in iiuid contact with the highly heated combustion products is of sulllcient duration to substantially completely removevthe vvaporizable carbonaceous contaminants associ'- catalyst type and 2 indicates a chamber for regenerating the used catalyst particles from reaction chamber l, in combination with a suitable form of apparatus for eiecting the purging operation pursuant to this inyention. The reaction chamberillustrated is of the type wherein the pulverulent, 'or powdered, catalyst is both sup-v being supplied to line I4 from line I5.

plied and withdrawn from the lower portion of the reaction chamber, this type being regarded as preferable. The process, however, is also applicable to those cracking conversion systems wherein both the used powdered catalyst and reaction vapors are withdrawn Aoverhead from the reaction chamber.

In the type of operation illustrated a suspen-A sion of the high-boiling hydrocarbon vapors to undergo treatment is supplied through line 3. These vapors pick up fresh and/or regenerated catalyst from the standpipe 4 whereafter both the hydrocarbon vapors and the catalyst are conveyed through transfer line 5 to a suitable disvand during their contact therewith undergo the desired conversion reaction. The vaporous reaction products are withdrawn through line 8 to a products recovery system not shown. Due to the extensive turbulence and internal recycle of the catalyst particles produced under these conditions by the reaction vapors, the catalyst is of substantial uniform composition throughout the dense phase bed, and may be suitably withdrawn from any point therein by gravity ow even from a lower portion thereof closely adjacent the incoming feed vapors by withdrawal passage 9, as illustrated. The catalyst is maintained in a uid condition while flowing through passage 9 by a suitable aeration medium supplied through valved line I 0 and the associated distributor Il. passageway 9, the catalyst is withdrawn through a suitable standpipe I2 in which the catalyst likewise may be maintained in a uid fiowable state by means of aerating iuid supplied through valved line I3.u Heretofore it has been the practice to depend upon the simple countercurrent stripping action effected by the aeration means such as is supplied through lines I0 and I3 to eifect the desired purging of the used catalyst.

Pursuant to the present process the used catalyst is passed to transfer line I4 by gravity iiow,

or otherwise, wherein it is picked up by a gaseous medium, such as steam, flue gas, air or the like, In its passage through this line, the catalyst may be maintained in a free-flowing state which preferably is amore dilute phase than that maintained either in dense phase bed 1 or standpipe I2. Line I4 connects with line I4', valve 35' being closed, which line terminates in an -upper part of regeneration Vchamber 2. at an intermediate point such as is indicated byv the numeral I6, whereupon the catalyst and the gaseous material enter the dilute catalyst phase of the upper bed I8 directly from regeneration sectlt'ln' lI9 of regeneration chamber 2 through dispersion means which may be a grid or constructed similar to the bubble caps common in the distillation of liquid materials, or otherwise. 'I'he quantity of gases and catalyst supplied to section I1 is such asfto produce a relatively dense turbulent fluidized phase of the catalyst in dense phase bed I8.

chamber I.

From

porizable material associated with the catalyst as the result of the cracking reaction in reaction The gases thereafter leave the system by way of line 30. Due to the extensive turbulence and internal recycle of the catalyst particles produced under these conditions, the catalyst is uniformly purged of vaporizable contami- Vnants and is of substantial uniform composition as to its associated unvaporized contaminants throughout the dense phase, and maybe sultably withdrawn from any point therein by gravity flow such as by passage 2l. The purged catalyst is introduced into dense phase bed 22 of section I9 of the regeneration chamber 2 preferably, but not necessarily, at a point below the top level, or interface 23 in quantities regulated by a control mechanism which may be a butteriiy valve 2l as shown on the drawing or any other suitable means.

An oxygen-containing gas, such as air, is supplied to the lower, or regeneration, section Il of regeneration chamber 2 through line 24 and distributing grid 25. A sufficient quantity of this gas is thus applied to maintain the catalyst in a dense fiuidized condition and to burn a desired amount of the deposit of unvaporized carbonaceous material from the purged catalyst particles. In dense phase bed 22, as in dense phase beds 1 and I8, the extensive turbulence and internal recycle of the catalyst particles, produced by the catalyst and gases `supplied to the bed, cause the unvaporized contaminants to be uniformly burned from the catalyst throughout the entire bed. This results in effecting a regenerated catalyst having a substantially uniform distribution of residual carbon content throughout the dense phase. Hence, the regenerated catalyst may be withdrawn at a controlled rate from any point therein by gravity flow, even from a lower portion of bed 22 closely adjacent the incoming oxygen-containing gas, by passage 26. The catalyst is maintained in a fluid condition while flowing through passage 25 by a suitable aerating medium supplied through valved line 21 and the associated distributor 28. From passage 26, the catalyst is withdrawn through a suitable standpipe 4 in which the catalyst also may be maintained in a uid owable state by means of aerating fluid supplied through vvalved line 29. It is sufiicient to depend upon the simple countercurrent stripping action effected by stripping means such as lines 21 and 29 to effect the desired purging of the regenerated catalyst prior to its introduction into the reaction charnberl through line 5.

Various modifications in the apparatus and process iiow illustrated in the drawing may -be employed. Pursuant to one modification combustion product gases are employed to convey the catalyst through line I4. As a preferable source of this material, a portion of the gas exiting thru line 30 is diverted therefrom through line -3I, having valve 32, and impelled therethrough by blower 33 to line I5. 'Ihe catalyst and conveying gas `thereafter are separated in the upper section I1 of regeneration chamber 2. If desired the flow of the catalyst particles in line I4 may be modifled as to pass to a cyclone separator 34 and the separation effected in this vessel. In this event the 1ine.gction I4' of line I4 may be omitted and replaced by line section II or, as shown on ythe drawing, the catalyst ilow may be diverted gaseous conveying medium is injected into line M from line I5 in quantities controlled by valve 38. According to this modicatlon, \tl1e catalyst preferably is separated from the steam in cyclone separator 34. Line 3l is then employed to vent the separated steam to withdrawal line 30 unless it is found desirable to recover` hydrocarbon constituents from the conveying medium. In this event line 38 may be omitted, or as shown on th drawing, valve l0 is closed, valve Il opened, and the vapors from cyclone 34 caused toilow through line 42 for introduction into the dilute catalyst. phase zone 43 of reaction chamber l. Recovery vof the hydrocarbon constituents is thereafter readily effected in the hydrocarbon recovery system, not shown on the drawing.

While the invention is not confinedto any particular theory of operation, theA improved results secured compared to those produced by simple countercurrent stripping which theoretically would be the optimum procedure, are believed to be due to several factors. One of these is the prolonged residence time of the catalyst particles in a physical state of aggregation and at a temperature greatly exceeding the temperature of the cracking reaction. This provides for the vaporization from the catalyst of carbonaceous material most difficult to vaporize either by'normal vaporization or by decomposition of the carbonaceous substance adsorbed by the catalyst particles. Further, the. foregoing eil'ect is enhanced by supplying the purging fluid, without the necessity of mechanical compression, substantially at the moment of its formation thereby utilizing the residual amount of uncombined` oxygen contained therein to assist in the decomposition of the .contaminants most dilcult to vaporize. As withdrawn from the cracking reaction, the catalyst particles normally will be at a temperature of about 850 to 950 F., and as withdrawn from the regeneration chamber at about 1000 to 1100 F. Hence, the hot product gases of combustion rising immediately through the dispersion means 20 will effectively maintain the catalyst particles in dense phase bed- I8 at a temperature of at least 1000 F. and provide for stripping at maximum temperature level existing in the system.

I claim:

1. In the method of catalytlcally converting hydrocarbons wherein catalyst in nely divided condition is contacted with a vaporous hydrocarbon undergoing conversion at an elevated temperature in a conversion zone for a period of time sufficient to effect the desired conversion reaction with resultant deposition of vaporizable and unvaporizable carbonaceous material on the catalyst and wherein catalyst removed from said conversion zone is contacted with an oxygen-containing gas in a `regeneration zone at a temperature higher than said temperature for conversion' to regenerate the catalyst for use in the conversion zone, the improvement which comprises withdrawing catalyst from the conversion zone. suspending the withdrawn' catalyst as af`dilute suspension in hot gaseous products 4oi/combustion from .a subsequent stripping zone-substanf 6. tially free of oxygen and at a temperature relatively higher than that in said conversion zone, passing and concurrently contacting the components of the resulting mixture of catalyst and gaseous products in an elongated conduit 0f restricted cross-sectional area whereby vaporizable carbonaceous deposits are stripped from said catalyst, then passing said resultant mixture into a stripping zone, maintaining in said stripping zone a lower dense fiuidized phase and an upper dilute phase of catalyst. said resulting mixture of suspended catalyst and gaseous products being introduced intosaid stripping zone at a point above the interface between said dense and dilute phases whereby the catalyst separates from said gaseous products and falls into said dense phase, passing hot gaseous products of combustion of relatively low. oxygen content from a subsequent catalyst regeneration upwardly through said dense iiuidized phase under conditions such that.

further vaporizable carbonaceous deposits are removed from the catalyst. removing from the dense uidized phase of said stripping zone cata'- lyst containing non-vaporized carbonaceous deposits thereon and passing same to said regeneration zone, subjecting said catalyst removed from the stripping zone to combustion conditions by contacting with a gaseous mixture of relatively high oxygen content whereby the unvaporized carbonaceous deposits are burned and the catalyst is regenerated, recovering regenerated catalyst from said regeneration zone, passing a gaseous effluentV from said regeneration zone directly to said hot stripping zone as said gaseous products of combustion of relatively low oxygen content, removing from the upper portion of said stripping zone a gaseous eiliuent and employing a portion thereof as said hot gaseous products of combustion substantially free of oxygen for use in suspending and concurrently contacting said catalyst removed from said conversion zone in.

catalyst and wherein catalyst removed from said` conversion zone is contacted with an oxygencontaining gas in the dense fluidized phase of catalyst in a regeneration zone at a temperature higher than said temperature for conversion to regenerate the catalyst for usein the conversion zone, the improvement which comprises withdrawing catalystfrom the conversion zone, suspending the Withdrawn catalyst as a dilute suspension in hot gaseous products of combustion from a subsequent stripping zone substantially free of oxygen and at a temperature relatively higher than that in said conversion zone, passing and concurrently contacting the components of the resulting mixture of catalyst and gaseous products in an elongated conduit of-restricted cross-sectional area whereby vaporizable carbonaceous deposits are stripped from said catalyst, then passing said resulting mixture into a stripping zone, maintaining in said strippng zone a lower dense iludized phase and an upper dilute phase of catalyst, said resulting mixture of suspended catalyst and gaseous products being introduced into said stripping zone at a point above the interfacev between said dense and dilute phases whereby the catalyst separates from said gaseous products and falls into said dense phase, passing hot gaseous products of combustion of relatively low oxygen content from a subsequent catalyst regeneration upwardly through said dense tluidized phase under conditions such that further vaporizable carbonaceous deposits are removed i'rom the catalyst, removing from the dense fiuidized phase of said stripping zone catalyst containing non-vaporized carbonaceous deposits thereon and passing same to said dense iluidized phase of catalyst in said regeneration zone, subjecting said catalyst removed from the stripping zone to combustion conditions by contacting with a gaseous mixture oi relatively high oxygen content whereby the unvaporized carbonaceous deposits are burned and the catalyst is regenerated, recovering regenerated catalyst from said dense uidized phase of catalyst in said regeneration zone, passing a gaseous effluent from said regeneration zone directly to said stripping zone as said hot gaseous products of combustion of relatively low oxygen content, removing from the upper portion of said stripping zone a gaseous eiiluent and employing a portion thereof as said hot gaseous products of combustion substantially free of oxygen for use in suspending and concurrently contacting said catalyst removed from said conversion zone in said elongated conduit.

3. In a lcatalytic conversion process wherein ilnely divided catalyst becomes contaminated with vaporizable and unvaporizable carbonaceous material and -wherein used catalyst from said conversion process is regenerated by being subjected to combustion with an oxygen-containing gas, the improvement which comprises suspending the used catalyst prior to regeneration as a dilute suspension in hot gaseous products of combustion substantially free of oxygen from a subsequent stripping zone. concurrently contacting and conveying the used catalyst with the hot gaseous products employed for said suspension in an elongated conduit of restricted cross-sectional area to a stripping zone whereby vaporizable carbonaceous material is stripped from the catalyst, maintaining in said stripping zone a lower dense uidzed phase and an upper dilute phase of catalyst, introducing the suspension of catalyst in said gaseous products into said dilute phase whereby the catalyst separates from the gaseous products and falls into said dense phase, passing hot gaseous products ofy combustion of relatively low oxygen content from a subsequent catalyst regeneration upwardly through said dense fluidized phase under conditions such that further vaporizable carbonaceous material is removed frorn the catalyst, removing from the dense fiuidized phase of said stripping zone catalyst containing non-vaporized carbonaceous material thereon and passing same to a regeneration zone, subjecting said catalyst from said stripping zone to combustion conditions with a gaseous mixture of relatively high oxygen content whereby the unvaporized carbonaceous material is burned and the catalyst is regenerated, recovering regenerated catalyst from said regeneration zone, passing a gaseous eiiiuent from said regeneration zone directly to said hot stripping zone as said gaseous products of combustion of relatively low oxygen content, removing from the upper portion of said stripping zone a gaseous efiluent and employing a portion thereof as said hot gaseous products of combustion substantially free of oxygen for use in suspending. con- 8 currently contacting and conveying s'aid used catalyst in said elongated conduit.

4. In the method of catalytically converting hydrocarbons wherein catalyst in iinely divided condition is contacted with a vaporous hydrocarbon undergoing conversion at an elevated temperature in a conversion'zone for a period of time suiiicient to effect the desired conversion reaction with resultant deposition of vaporizable and unvaporizable carbonaceous material on the catalyst and wherein catalyst removed from said conversion zone is contacted with an oxygencontaining gas in a regeneration zone at a temperature higher than said temperature for conversion to regenerate the catalyst for use in the conversion zone; the improvement which comprises withdrawing catalyst from the conversion zone, suspending the 'withdrawn catalyst as a dilute suspension in hot gaseous products oi combustion. substantially free of oxygen and at a temperature relatively higher than that in said conversion zone, from a subsequent stripping zone, concurrently contacting the components of said suspension in an elongated conduit ot restricted cross-sectional area whereby vaporizable carbonaceous material is stripped from the catalyst, passing said components to a catalyst separating zone and separating therein the catalyst from said gaseous products and stripped vaporizable carbonaceous material, passing the thus separated catalyst to a stripping zone, maintaining in said stripping zone a lower dense iluidizedl phase and an upper dilute phase of catalyst, passing hot gaseous products of combustion of relatively low oxygen content from a subsequent catalyst regeneration upwardly through said dense fluidized phase under conditions such that further vaporizable material is removed from the catalyst, removing from the dense fluidized phase of said stripping zone catalyst containing non-vaporized carbonaceous material thereon and passing same to saldregeneration zone, subjecting said catalyst removed from rthe stripping zone to combustion conditions by contacting with a gaseous mixture of relatively high oxygen content whereby the unvaporized carbonaceous material is burned and the catalyst is regenerated, recovering regenerated catalyst from said regeneration zone. passing a gaseous eilluent from said regeneration zone directly to said stripping zone as said hot gaseous products of combustion of relatively low oxygen 'content, removing from the upper portion of gonhydrocarbons wherein catalyst in iinely divided condition is contacted with a vaporous hydrocarbon undergoing conversion at an elevated temperature in a conversion zone for a period of time suilicient to effect the desired conversion reaction with resultant deposition of vaporizable and unvaporizable carbonaceous material on the catalyst and wherein catalyst removed from said conversion zone is contacted with an oxygen-containing gas in a regeneration zone at a temperature higher than said temperature for conversion to vregenerate the catalyst for use in the conversion zone; the improvement lwhich comprises withdrawing catalyst from the conversion zone. suspending the withdrawn catalyst as a dilute suspension in hot gaseous products ofcombus- 9 tion, substantially free of oxygen and at a temperature relatively higher than that in said conversion zone, from a subsequent stripping zone, concurrently contacting the components of said suspension in an elongated conduit of restricted cross-sectional area whereby vaporizable carbonaceous material is stripped from the catalyst, passing said components to a catalyst separating zone and separating therein the catalyst from said gaseous products and stripped vaporizable carbonaceous material, passing the thus separated catalyst to a stripping zone maintaining in said stripping zone a lower dense uidized phase and an upperV dilute phase of catalyst, passing the thus separated catalyst directly into said lower dense uidized phase of the stripping zone, passing hot gaseous products of combustion of relatively low oxygen content from a subsequent catalyst regeneration upwardly through said dense uidized phase under conditions such that further vaporizable material is removed from the catalyst, removing from the dense uidized phase of said stripping zone catalyst containing non-vaporized carbonaceous material thereon and passing same to said regeneration zone, subjecting said catalyst removed from the stripping zone to combustion conditions by contacting with a gaseous mixture of relatively high oxygen content whereby the unvaporized carbonaceous material is burned and the catalyst is regenerated, recovering regenerated catalyst from said regeneration zone, passing a gaseous eiiiuent from said regeneration zone directly to said stripping zone as said hot gaseous products of combustion of relatively low oxygen content; lremoving from the upper portion of said stripping zone a gaseous efiiuent and employing a portion thereof as said hot gaseous products of combustion substantially free of oxygen for use in concurrently contacting said dilute suspension of catalyst in said elongated conduit.` l JOSEPHW. MOORMAN.

lnnlvnmfsisrcns CITED The following references are of record in th I le of this patent:

UNITED STATES PATENTS Number Name Date 2,253,486 Belchetz Aug. 19, 1941 2,289,329 Prickett July '7, 1942 2,367,281 Johnson Jan. 16, 1945 2,385,326 Bailey Sept. 25, 1945 2,429,359 Kassel Oct. 21, 1947 

